Composite heat-insulating sheet



l D. W. PYIE. corwPosaTr-i HEAT INSULATING SHEET APPLICATION FILED DEC.I5, I9I8.

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Specification of Letters Patent.

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.llpplication 'tiled 'lllecember lo, tutti. terial Lillo. itt-36h53. A

To all cli/tom t may concern:

Be it known that ll, DAVID W.. lmrn, a citizen of the lUnited States,and a resident of Red Banti, county of Monmouth, and

tritate of New Jersey, have invented certain new and useful lmprovementsin llomposite Heat-insulating fdheets, of which the following is a full,clear, concise, and enactV description, such as will'enable othersskilled in the art to which the invention relates to make and use thesame, reference being made therein to the accompanying drawings, whichform apart of this specification.

My invention relates to composite sheets made up of a main body portionof felted material, together with a protecting or backing sheet of othermaterial overlying the yp felt body portion and serving to protect theHtl lll ti same, and also to strengthen the same to a greater or lessdegree; .and the object ofmy invention is to provide a composite heatinsulating sheet, quilt, or fabric'of the type above referred to whichisformed of' amain body. portion of felted material secured to which isa layer or sheet of paper, the two being joined together by forcing aneedle or similar article through the felted material and through thelayer of paper whereby fibers of the felted material are .forced throughthe punctured openings in the paperv and firmly clasped by the edges ofsaid openings as the needle is withdrawn.

\ A further object is to provide a heat insulating sheet or fabricwherein the reinforcing baclring sheet is formed of paper, so as to beimpervious to liquids, whereby cemena-paint, varnish, or other liquidcomposition, may be applied to the paper paclring lll@ and thus anchorthe protruding fibers of the feltedl material to the paper backing andwithout danger' of the felted material ab-` protecting coating duringits apovercome these difficulties by providing an imperforate backingsheet of paper and carrying fibers of the threaded material.

through minute punctures in the paper backing," the sides of thepunctures closing` againstv the fibers as the puncturing instrument iswithdrawn, thereby locking the fibers to the backing sheet of paper andrendering the entire article impervious to moisture, and further,allowing a liquid coating such as paint, varnish, cement, or otherdesirable material, to be applied to the backing sheet without causingthe felted material to absorb the same, which latter would materiallyinterfere with the heat insulatj ing properties of the article.

lilly inventionv is regarded as including a composite sheet having thecharacteristics above pointed out, as well also as the method or processwhereby the same is manufactured or produced, all as hereinafterexplained in detail and particularly claimed in the coni cluding claims.

lily invention has special reference to the provision of a `compositesheet or fabric made up for the most part of felt material, and designedfor use about metallic railway cars, in order to prevent the flow ofheat or cold through the wall thereof; although it will be appreciatedthat the same may be used in any place where it is desired to preventthe flow of heat from one body to an other', may be used to lessen thetransmission of sound through a floor, wall, partition, or

other structure, or for any and all other pur-4 poses for which such acomposite sheet is adapted. lin the innl a part of this specication:

ligure l is a perspective viewl illustrating a section of a compositesheet made in acp cordance with my invention;

' 2 is a view showing a section of the sheet, the surface of thecovering or strengthening layer thereof being coated with a suitJ ablecement material;

'lliig 3 is a view showing a section of a thicker sheet made up bysecuring two such sheets as are shown in Figs. l or 2 together, byquilting; and

ig. l is a view illustrating the process of manufacture whereby myimproved composite sheeting is produced.

Referring to the drawing, the reference,

numeral 5 designates the main bodyl portion of niy improved compositesheet, the same.

drawing accompanying and formtill lill

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being of felt material produced by felting hair or other fiber ormaterial which will felt into a compact mass of considerable thicknessin accordance with any of the well known felting processes; the mannerin which the felt layer is produced being of secondary importance, andnot involved in this present invention.

The reference numeral 6 designates a .strengthening or protecting sheetoverlying the'body of felted material 5 and affording protection to thesame, and, incidentally, more or less contributing to the strength ofthe felt material and of the composite sheet of which it forms theprincipal part. Furthermore, the protecting sheet provides a sheet tosecure them together as hereinbefore pointed out; this end beingaccomplished by placing the felt body portion upon the strengtheningsheet, and then forcing a needle 7 or equivalent implement through thetwo, whereby fibers of the felt body portion are carried therefromthrough holes made by the needle in the protecting sheet; the needleboth forming the holes in said Y sheet and carrying the fibers from thefelt through the holes, as illustrated in said figure. Whileindescribing the method whereby the felt body portion and protecting layerare secured together I have referred to a single needleor equivalentpiercing member, it will be appreciated that in practice a large numberof such members will be assembled in a single holder designed andarranged to operate upon the fabric, to thereby provide a device forsecuring the felt ybody portion and protecting sheet together ra idlyand efficiently.

n the finished sheet the protecting layer will be secured to the mainfelt body portion at a large number of places throughout the area of thecomposite sheet, as shown in l Fig. 1 the distance apart of the separatefastenmgs thus provided being largely a i matter of choice, anddependent obviously upon the degree of security with which the felt andthe overlying protecting sheet are to be fastened one to the other.

In va composite sheet such as is shown in Fig. 1, the backing materialor sheet 6 will be secured to the felt body portion with sufcientsecurity for many purposes, and a sheet of the form in which it is shownmay be used without further treatment for many purposes. I prefer,however, to coat the exposed surface of the sheet 6 with a suitablecementitious material 8 to thereby secure the fibers 9 and the sheet 6together more effectively, and to provide .a smoother exterior surfacefor the finished sheet; the material thus applied serving to smooth theburs produced in the protecting sheet by the needle 7, to fill the holesl0 around the fibers 8, to fasten the fibers themselves to the exposedsurface of the sheet, and to coat the sheet, as will be appreciated;thus providing a more finished sheet and one which will present a more`pleasing appearance. The resulting sheet may also be more readilymanipulated in installing the same because of the presence of thecoating material, and a certain degree of additional protection willbesecured by the use thereof. The coating material in question may be asuitable cement, paint, varnish, or in fact any liquid coatingcomposition which will accomplish the ends above mentioned.

The reinforcing sheet is preferably formed of some nonporous paper whichis impervious to moisture and will absorb but little of the cement,paint, or varnish of the coating composition. Further, the papermatcrial increases the heat-insulating properties of the article, inthat it prevents any air from circulating therethrough.

Fig. 2 shows a composite sheet made in accordance with my invention andin which .a coating cementitious material 8 has been applied to theexposed outer surface of the protecting sheet 6, as above pointed out;and which sheet may be used in the form thus produced for many purposes.I prefer,

however, to secure two such composite sheets -as are shown in Fig. 2together with their felted body portions in contact with' one another,as shown in Fig. 3, the two sheets being preferably Secured together byrows of stitches, as shown at 11, as in ordinary quilting operations.This obviously produces a much thicker sheet and one more effective forheat insulation, sound deadening, or other purposes for which suchsheets are used; and, furthermore, produces a composite sheet, in whichboth exterior faces are protected by overlying strengthening orprotecting sheets, as heretofore explained. The exposed surfaces of theprotecting sheets are themselves shown as protected, and a more firmbond secured between them and the felted body portions, by means of anexterior coating of cement, paint, varnish, or other material, ashereinbefore explained. The cementitious material employed in producingthe composite sheet wherein my invention consists is preferably amaterial having fire-proofing qualities, from which it follows that, inaddition. to the function nate-eea which the said material performs in'providing a more firm bond between the protecting backing Sheet orsheets 6 and the main body of felt material upon which it lies., itprovides a composite sheet which Will have fireresisting qualities to aVery considerable extent the protecting sheet and the cementitiousmaterial upon the surface thereof thus imparting fireproof orfire-resisting qualities to the main felt body portion ofl the sheet toa marked degree.

li-laving thus described and explained my invention, l claim and desireto secure by lietters Patent:

l. A heat insulating article of the class described comprising a bodyportion of felted material, a sheet of paper overlying said lelted bodyportion and forming a protecting baclring, fibers of the felted materialextending through minute punctures in said paper sheet and a coating ofcementittons material upon the exposed surface of said protecting sheetof paper, embedding the protruding fibers therein.

2. A heat insulating article of the class described comprising a bodyportion of felted material a protecting backing sheet of paperoverlyingsaid felted body portion, fibers of the felted materialextending through minute punctures in said paper sheet, the side wallsof the punc-tures closed and gripping said fibers and preventing theabsorption of a cementitious material by the felted material, and acoating of cementitious materialv upon the exposed surface of saidprotecting sheet of paper and embedding and anchoring the protrudingfibers of the felted material thereto.

ln testimony whereof ll have signed my name to this specification thisllth day of December, 1918.

Dl-llliD W.. PYE..

